Tented gas burner for grill

ABSTRACT

A grill having a bi-level tent configuration, a burner assembly and a grill shell. The lower, first tent has an “I”-shaped configuration. The upper, second tent has a plurality of openings. The burner assembly is formed from stamped metal. The upper piece of stamped metal has a raised or embossed area with multi-level ports. The burner and tent arrangement provides even distribution of heat to the cooking surface and flare-up control. The use of stamped metal for the burner assembly provides for a cost efficient and easy to assemble grill.

FIELD OF THE INVENTION

[0001] The present invention relates to gas barbecue grills generallyand more particularly to burners and tented burners for grills.

BACKGROUND INFORMATION

[0002] In general, it is known to use tented burners in barbecue grills.However, presently available barbecue grills have several disadvantages.For example, known tented burner arrangements are ineffective inproviding an optimum and even distribution of heat to the cookingsurface of the grill. In addition, presently available grills do noteffectively control flare-ups, as are commonly caused by drippings ontothe burner or the tent arranged above the burner.

SUMMARY OF THE INVENTION

[0003] The present invention provides a grill having a tent structuremounted over a gas burner. The tent structure is configured in such away as to allow the periphery of the cooking surface to achieve a highertemperature than that allowed by conventional tented burnerarrangements, thereby providing an even distribution of heat to thecooking surface of the grill.

[0004] The present invention also provides a grill having a tent orcombination of tents to provide improved flare-up control.

[0005] In addition, the present invention provides a gas grill having astamped sheet metal burner assembly with top-side, multi-level portingto enhance even distribution of heat across the cooking surface. Thisresults in a low-volume, efficient burner having a longer operatinglifespan. Moreover, the use of sheet metal components providessubstantial cost and assembly benefits.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 is an exploded perspective view of an exemplary embodimentof a grill in accordance with the present invention.

[0007]FIG. 2 is an exploded perspective view of the burner assembly ofFIG. 1.

[0008]FIG. 3A shows an exploded perspective view of a venturisub-assembly in accordance with the present invention. FIGS. 3B and 3Care bottom and side views, respectively, of a portion of the venturisub-assembly.

[0009]FIG. 4 is a cross-sectional view of the gas grill of FIG. 1.

[0010]FIG. 5 is a cross-sectional view of a further embodiment of a gasgrill of the present invention.

DETAILED DESCRIPTION

[0011] The present invention is directed to a burner arrangement for agas grill. As shown in FIGS. 1-3 an exemplary embodiment of the gasgrill comprises a bi-level tent configuration, a burner assembly 1, anda main grill shell 2.

[0012] A lower, first tent 3 is generally configured in the shape of theletter “I”. A main, central portion of the first tent 3 comprises afirst sloped surface 4 and a second sloped surface 5 which meet along aridge 6. In the exemplary embodiment shown, the sloped surfaces 4 and 5are arranged with an angle of approximately 120 degrees therebetween. Oneach end of the main portion of the first tent 3 is a transversetent-like structure 7 a, b. Each transverse tent segment 7 a, bcomprises an outer sloped surface 8 a, b and a medial sloped surface 9a, b which meet along a ridge 10 a, b. The ridges 10 a, b aresubstantially perpendicular to the central ridge 6. A mounting tab 11 a,b for mounting the tent 3 to the grill shell 2 is arranged at a lowerend of each sloped surface 8 a, b. Each mounting tab 11 a, b maycomprise a hole for receiving a fastener therethrough. Proximate to theends of the medial sloped surfaces 9 a, b, openings 12 a, b, c, d areprovide for securing an upper tent structure 15, described below.

[0013] The first tent 3 maximizes heat distribution, especially to thecorners and to the periphery of the cooking surface. The tent 3 alsoprevents grease or other food drippings from contacting the burner 1,thus protecting the burner 1 and effectively eliminating or controllingflare-ups. By thus protecting the burner 1, it becomes possible toprovide flame ports on the top side of the burner 1, which substantiallyimproves the longevity of the burner.

[0014] An upper, second tent 15 comprises a first sloped surface 16 anda second sloped surface 17 on opposite sides of a ridge 18. The secondtent preferably comprises a plurality of openings 19 arranged throughthe first and second sloped surfaces 16 and 17. The openings 19 provideimproved heat distribution and allow for controlled flare-ups.

[0015] The second tent 15 is arranged over the center section of thelower tent 3 with an air gap therebetween. In the exemplary embodimentshown, the sloped surfaces 16 and 17 are arranged with an angle ofapproximately 130 degrees therebetween and the tents 3 and 15 are spacedapart at their ridges (e.g., 0.02″ to 0.50″). The air gap between thetents 3 and 15 cools the tents, particularly the upper tent 15, whichhelps control flare-ups. The gap between the tents also preventsdrippings and food particulates from becoming trapped between the tents.The arrangement of the second tent 15 over the tent 3 also promotes aneven distribution of heat to the cooking surface and allows grease todrain from the cooking surface, thereby reducing flare-ups.

[0016] At its corners, the second tent 15 preferably comprises tabextensions 20 a, b, c, d. When the tent 15 is placed on the lower tent3, the tab extensions 20 a, b, c, d sit in the openings 12 a, b, c, d onthe first tent 3. The tent 15 is readily removable from the lower tent 3such as for cleaning.

[0017] The burner assembly 1 will now be described. As shown in FIG. 1,the burner assembly 1 comprises a burner sub-assembly 40 and a venturisub-assembly 25, each of which is comprised of stamped sheet metalcomponents. As shown in FIG. 2, the burner 1 is assembled by capturingthe venturi sub-assembly 25 between upper and lower halves of the burnersub-assembly 40. The lower half of the burner sub-assembly 40 iscomprised of a stamped piece of sheet metal 21. The upper half of theburner sub-assembly 40 is comprised of a complementary piece of stampedsheet metal 22. The two halves are preferably joined by staking orhemming the two pieces together.

[0018] The upper piece of sheet metal 22 comprises raised or embossedfeatures 26 a and 26 b, whereas the lower piece 21 comprisescorresponding embossed features 27 a and 27 b. Each feature 26 a, b and27 a, b is formed as a channel arranged in an elongated oval loop. Theperipheries of the features 26 a and 26 b substantially correspond tothe peripheries of the features 27 a and 27 b, respectively. When thetwo pieces 21 and 22 are joined, the features 26 a, b and 27 a, b formtwo hollow burner halves 41 a and 41 b, as shown in FIG. 1.

[0019] As shown in FIG. 2, the features 26 a, b of the upper burnerportion 22 comprise a plurality of holes or ports 24. The ports 24preferably are arranged in a plurality of rows on each of the features26 a, b. In one embodiment, a first row of ports 24 is located on sidewalls of each feature 26 a, b and a second row of ports 24 is locatedabove the first row, near the junction of the side walls and asubstantially flat top surface of the feature 26 a, b. The ports 24arranged in the second row are preferably smaller than the ports in thefirst row. Such multi-level porting improves the efficiency of theburner and provides better heat distribution at the cooking surface ofthe grill. Furthermore, locating the ports 24 on the top side of theburner also improves burner performance and efficiency and substantiallyimproves the longevity of the burner, as compared to conventionalburners which are ported on their undersides.

[0020] The gas burner sub-assembly 40 also may comprise elongatedslot-like openings 30 through the two pieces of stamped metal 21, 22.The elongated slot-like openings 30 provide additional secondary air toenhance the performance of the gas burner assembly 1, in particularimproving the burning which occurs through the ports 24 located on ornear the essentially horizontal top surfaces of the features 26 a, b ofthe burner sub-assembly 40.

[0021] In the exemplary embodiment shown in FIG. 2, the lower and upperpieces 21 and 22 of the burner sub-assembly 40 comprise tabs 28 a, b and29 a, b, respectively, at opposite ends. When the pieces 21 and 22 arejoined, the tabs 28 and 29 are joined and may be used to mount theburner 1 to the grill shell 2. As shown in FIG. 1, the grill shell 2 maycomprise openings 33 for receiving the tabs 28 and 29.

[0022] The gas burner assembly 1 also comprises a venturi sub-assembly25. As shown in FIG. 3, the venturi sub-assembly 25 preferably comprisestwo pieces of stamped metal 25 t and 26 b which are joined, such as byhemming or staking, to form two fuel-air passages, one for each burnerhalf 41 a, b. Each passage provides a conduit for providing an air-fuelmixture to each burner half.

[0023] As shown in FIG. 3A and enlarged in FIGS. 3B and 3C, the venturisub-assembly 25 preferably also comprises louvers 251 proximate to theinlets of the fuel-air passages. The louvers 251 comprise openings whichallow primary air to be drawn into the passages. The primary air ismixed with fuel applied to the passage inlets and the fuel-air mixtureis conducted to the burner halves where it is combusted. The use ofprimary air helps make it possible to reduce the volume of the burner.The louvers 251 are preferably arranged on the lower portion 25 b of theventuri sub-assembly so as to shelter them from the elements (e.g.,wind, rain). Moreover, the louver openings preferably should besufficiently small so as to prevent insects from entering the passagesand nesting in the burner assembly 1.

[0024] When the burner assembly 1 is assembled, the venturi sub-assembly25 is captured between the two pieces 21 and 22 of the burnersub-assembly. The venturi passages align with the burner halves 41 a, bthus formed. An opening 37 in the venturi sub-assembly aligns withopenings 36 in the pieces 21 and 22 so as to provide an opening in thecompleted burner assembly 1 for receiving one or more ignitors, asdescribed below.

[0025] The stamped metal configuration of the burner assembly 1 allowsfor reduced manufacturing costs and ease of assembly compared to tubularsteel.

[0026] As shown in FIGS. 4 and 6, the burner assembly 1 may alsocomprise an ignitor sub-assembly which preferably is located in themiddle of the burner assembly 1. The ignitor sub-assembly may comprise apair of ignitors 34 placed through an opening 36 located between theburner halves 41 a and 41 b. For ignition, an arc is developed betweenthe electrodes of the ignitors 34. As shown in FIG. 6, the electrodes ofthe ignitors 34 are offset, thereby increasing the spacing between theelectrodes. The increased spacing results in the generation of longerarcs which improves ignition. Moreover, a collector box 50 is arrangedover the electrodes to improve the distribution of gas to the electrodesand to act as a windscreen. As shown in FIG. 4, the box 50 has an openback side which allows gas from the burner halves 41 a and 41 b to enterthe box where it is trapped and ignited by the electrodes 34. To furtherimprove the ignition operation, there may be an increased density ofports 24 on the burner halves 41 a, b proximate to the collector box 50.The use of the collector box 50 and the dual ignitors 34 allowsconsistent, reliable and fast ignition.

[0027] Although a dual-burner embodiment has thus far been described,other configurations, such as a single-burner or a three-burnerconfiguration are possible within the scope of the present invention.

[0028] The grill shell 2 is generally rectangular comprising two sets ofopposing walls and a floor. A front wall 30 a comprises one or moreopenings 31 through which the venturi sub-assembly 25 may pass. A bottomsurface of the shell 2 comprises two rectangular openings 35 which allowsecondary air to flow up through the bottom of the shell over the burner1. The shell 2 may also comprise features for suspending one or moregrease catches (not shown) below the openings 35. In the dual-burnerembodiment shown it is preferable to provide two smaller catches asopposed to one larger catch so as to provide better grease collectionand air flow through the openings 35. The improved air flow helps coolthe shell, thereby reducing flare-ups caused by grease trapped in theshell, and improves the provision of secondary air to the burner 1.

[0029] The grill shell 2 may comprise a tent pedestal 32 on each end.Each mounting tab 11 a, b on the first tent 3 rests on, oralternatively, is attached to a tent pedestal 32, positioning the firsttent 3 above the gas burner assembly 1, as shown in FIG. 4.

[0030]FIG. 5 shows a further embodiment of a grill in accordance withthe present invention. In the embodiment of FIG. 5, the tent 3 comprisesa horizontal plate 13 arranged at the base of the tent between thesloped surfaces 4 and 5. The plate 13 helps spread the heat generated bythe burner, keeping the tent 3 cooler. Additionally, refractoryelements, which absorb and re-radiate heat such as ceramic “hot blocks,”may be placed between the tent 3 and the plate 13 on the top side of theplate 13, to assist in the distribution of heat.

[0031] While several preferred embodiments of a tented gas burner for agrill have been described herein, it is to be understood that variationsmay be made in the tented gas burner assembly without departing from thespirit and scope of the invention as defined by the appended claims.

What is claimed is:
 1. A burner tent comprising: a central tent segment;a first peripheral tent segment, the first peripheral tent segment beingarranged at a first end of the central tent segment and beingsubstantially perpendicular to the central tent segment; and a secondperipheral tent segment, the second peripheral tent segment beingarranged at a second end of the central tent segment and beingsubstantially perpendicular to the central tent segment, wherein eachtent segment includes first and second sloping sides.
 2. The burner tentof claim 1, comprising a further burner tent, wherein the further burnertent is mounted over the burner tent and wherein the further burnerincludes sloping sides.
 3. The burner tent of claim 2, wherein aplurality of openings are arranged on the sloping sides of the furtherburner tent.
 4. The burner tent of claim 1 comprising a further surfacearranged between the first and second sloping sides of the central tentsegment.
 5. A burner assembly comprising: a burner sub-assembly, whereinthe burner sub-assembly includes a first embossed sheet metal portionand a second embossed sheet metal portion; and a venturi passagesub-assembly, wherein the venturi passage sub-assembly includes a thirdembossed sheet metal portion and a fourth embossed sheet metal portion,wherein the venturi passage sub-assembly includes at least one passageand wherein the burner sub-assembly includes at least one hollowchamber, the at least one passage being in fluid communication with theat least one hollow chamber.
 6. The burner assembly of claim 5, whereinthe venturi passage sub-assembly is attached to the burner sub-assemblyby being captured between the first and second embossed sheet metalportions.
 7. The burner assembly of claim 5, wherein the first embossedsheet metal portion and the second embossed sheet metal portion arestaked together and wherein the third embossed sheet metal portion andthe fourth embossed sheet metal portion are staked together.
 8. Theburner assembly of claim 5, wherein the first embossed sheet metalportion comprises a plurality of openings.
 9. The burner assembly ofclaim 8, wherein the openings are arranged in a plurality of rows. 10.The burner assembly of claim 5, wherein the first and second embossedsheet metal portions each comprise an elongated opening.
 11. The burnerassembly of claim 5 comprising an ignitor sub-assembly, the ignitorsub-assembly including at least one ignitor electrode and a collectorbox, the collector box being arranged over the at least one ignitor. 12.The burner assembly of claim 5, wherein the at least one passage of theventuri passage sub-assembly includes at least one louver.
 13. A grillcomprising: a burner assembly; a first burner tent mounted above theburner assembly; and a second burner tent mounted above the first burnertent, wherein the first burner tent comprises a central tent segment, afirst peripheral tent segment, and a second peripheral tent segment, thefirst and second peripheral tent segments being substantiallyperpendicular to the central tent segment and each tent segmentincluding first and second sloping sides and wherein the burner assemblycomprises a venturi sub-assembly and a burner sub-assembly, each ofwhich is comprised of sheet metal.